IJSRD - International Journal for Scientific Research & Development Vol. 4, Issue 05, 2016 ISSN (online):

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1 IJSRD - International Journal for Scientific Research & Development Vol. 4, Issue 0, 016 ISSN (online): Optimization of Heat Transfer Coefficient of Air Preheater using Computational Fluid Dynamics Vivek Borkar 1 Shadab Imam Vikky Kumhar 1 PG Scholar Assistant Professor Lecturer 1,, Department of Mechanical Engineering 1, Cristian College of Engineering and Technology, Bhilai, INDIA RSR Rungta College of Engineering and Technology, Bhilai, INDIA Abstract After studying literatures mentioned in the literature review chapter, it is understood that there are some gaps in design of shell and tube air preheater. The main aim of the project investigation is to modify the design of air preheater, mentioned in Das et al. [40] to increase its heat transfer coefficient and hence improving its performance and efficiency. The tubular preheater ducts for cold and hot air require more space and structural supports than a rotating preheater design. Further, due to dust-laden abrasive flue gases, the tubes outside the ducting wear out faster on the side facing the gas current. Many advances have been made to eliminate this problem such as the use of ceramic and hardened steel. This project also contains the method for calculating boiler efficiency using indirect method and reduce the losses in air preheater by changing the tube diameter of air preheater in ANSYS Fluent (CFD) software and validating its results from literature Das et al. [40]. Key words: CFD, ANSYS I. INTRODUCTION A primary air heater is a tubular air heater which is arranged in the form of cross-flow heat exchanger. Many primary air heaters are used in coal-fired power plants, Steel manufacturing industries, power plant etc. The cross-flow air heater is very popular due to its low cost and eases of cleaning, operating and maintaining. Normally, the heat exchanger (known as the primary air heater) is recovered heat from the high flue gas to warm up the combustion air to ensure the coal is dried before transporting to the furnace. This heat exchanger is operated under high particulate conditions where fly ash from the combustion process tends to decrease its performance. Unfortunately, there is lack of data about the performance decreasing due to this condition. For boiler & furnace air is a primary component. In each of this equipment, the ambient air is required to be heated up to high s. Preheating the incoming air largely improves the thermal efficiency of the system, therefore, it increases the energy savings of the industry and as a results lower operating costs. In fact, every 0 rise in combustion air increases the boiler efficiency by nearly 1%. Heat exchangers can be used to recover the heat from various processes to preheat the air. However, the heat transfer coefficient of air is low and hence, fins or extended surfaces are used to enhance the heat transfer. It is a common industrial practice to utilize the heat of exhaust gases or flue gases and process steam to preheat ambient air. Air pre-heater is the most common equipment responsible for deterioration in boiler efficiency and increase in auxiliary power consumption in ID (Induced draft), FD (Forced draft), and PA (Primary air) fans. [] Fig. 1.1: Air Preheater [] An air preheater (APH) is a general term used to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. They may be used alone or to replace a recuperative heat system A. Types Of Air Preheater: There are mainly two types of air preheater on the basis of operating principle. 1) Recuperative Air Preheater: In such type of air preheater, heat is transferred continuously and directly through stationary, solid heat transfer surface which separate the hot flow steam from cold flow steam. The common heat transfer surfaces are tubes & parallel plates. [0] a) Tubular Air Preheater: In such type energy is transferred from the hot flue gas flowing inside thin walled tubes to the cold combustion air flowing outside the tubes. The unit is consist of nest of straight tube that are rolled or welded into tube sheets & enclosed in a steel casing or gas passing outside of the tubes & has both air and gas inlet & outlet openings. All rights reserved by 0

2 (IJSRD/Vol. 4/Issue 0/016/009) Fig. 1.: Tubular Air Preheater []. ) Regenerative Air Preheater: This type is relatively compact and are the most widely used type for combustion air pre heating in electric utility steam generating plants. Air to gas leakage can be controlled by cold presenting axial and radial seal plates to minimize gaps at the hot operating condition or using sacrificial material []. There are two types of regenerative air preheaters: the rotating-plate regenerative air preheaters (RAPH) and the stationary-plate regenerative air preheaters (Rothemuhle). Fig. 1.: Typical Rotating-plate Regenerative Air Preheater (Bi-sector type) II. LITERATURE REVIEW Dilip Patel (01), The Ljungstrom air preheater is a regenerative type heat exchanger used for preheating the combustion air, mainly in steam power plant. The warm gas and cool air ducts are arranged to allow both the flue gas and inlet air to flow simultaneously through the air preheater. The hot flue gas heats the rotor material and as the rotor rotates, the hot rotor section moves into the flow of the cold air and preheats it. If the incoming air is not preheated, then some additional energy must be supplied to heat the air to a required to facilitate combustion. Due to this, more fuel will be consumed which decreases overall efficiency of the power plant. In this paper different techniques used to optimize the process parameters of rotary regenerator are discussed. Taware khushal (01), In these result increase the efficiency of boiler by increasing no of tubes &adding super heater. Boiler efficiency also increased by reducing heat losses & increasing heat input. This heat input is increased by adding oxygen in the furnace area so more heat input is transferred to boiler process so increases the efficiency of boiler. By increasing length of tube boiler & adding super heater boiler gives max heat input to the process so increases ton capacity of boiler. In this way we get profit by increasing efficiency of boiler. M.Nageswara Rao (01), In these investigation the following points are concluded: 1) Thermal design of Air preheater model is cross verified by NTU method ) Air and Gas outlet from experiment are 4 C and 46 C which are close to that obtained by NTU method 466 c and 49. C The difference in the may be due to fouling in gas and distribution of flow due to vibration of the system Chayalakshmi C.L (01), The traditional method for calculation of boiler efficiency using indirect method involves complex mathematical equations, which is a tedious work for operation department people of an industry. Instead of manual calculation, the software system developed in this paper can be easily adopted which provides measurement and monitoring of various losses and boiler efficiency. In indirect method, no need to measure or monitor the parameters which are necessary for finding boiler efficiency and boiler design cannot depict its efficiency. As the performance evaluation of boiler is based on its boiler efficiency, finding boiler efficiency using indirect method is an easy task if the developed application software is used. The error between the boiler efficiency calculated using conventional method and the calculated using application software is very small. Calculation of boiler losses and efficiency is carried out using DASY Lab software package and tested with data obtained from industrial environment. III. METHODOLOGY A. Governing Equations of Fluid Flow and Heat Transfer: Following fundamental laws can be used to derive governing differential equations that are solved in a Computational Fluid Dynamics (CFD) study [1] conservation of mass conservation of linear momentum (Newton's second law) conservation of energy (First law of thermodynamics) In this course we ll consider the motion of single phase fluids, i.e. either liquid or gas, and we'll treat them as continuum. The three primary unknowns that can be obtained by solving these equations are (actually there are five scalar unknowns if we count the three velocity components separately) Velocity vector V Pressure p Temperature T All rights reserved by 1

3 (IJSRD/Vol. 4/Issue 0/016/009) But in the governing equations that we solve numerically following four additional variables appear Density ρ Enthalpy h (or internal energy e) Viscosity μ Thermal conductivity k Pressure and can be treated as two independent thermodynamic variables that define the equilibrium state of the fluid. Four additional variables listed above are determined in terms of pressure and using tables, charts or additional equations. However, for many problems it is possible to consider ρ,μ and k to be constants and to be proportional to with the proportionally constant being the specific heat. Due to different mathematical characters of governing equations for compressible and incompressible flows, CFD codes are usually written for only one of them. It is not common to find a code that can effectively and accurately work in both compressible and incompressible flow regimes. In the following two sections we'll provide differential forms of the governing equations used to study compressible and incompressible flows. B. Heat Exchangers: Heat Exchangers are classified according to their function and geometry: Function: Recuperative: two fluids separated by a solid wall Evaporative: enthalpy of evaporation of one fluid is used to heat or cool the other fluid. Regenerative: use a third material which stores/releases heat Geometry: 1) Double Tube ) Shell and Tube ) Cross-flow Heat Exchangers 4) Compact Heat Exchangers The heat transfer rate for most heat exchangers can be calculated using the LMTD-method (Log Mean Temperature Difference), if the inlet (T1) and outlet (T) s are known: Q = UA T T = T T 1 ln ( T / T 1 ) F Where, U = Overall heat transfer coefficient [ W/m-oC ] A = Effective heat transfer surface area [ m ] F = Geometry correction factor T = Log mean difference C. Cross Flow And Compact Heat Exchangers: Cross-flow and compact heat exchangers are used where space is limited. These aim to maximize the heat transfer surface area. Commonly used in gas (air) heating applications. The heat transfer is influenced by whether the fluids are unmixed (i.e. confined in a channel) or mixed (i.e. not confined, hence free to contact several different heat transfer surfaces). In a cross-flow heat exchanger the direction of fluids is perpendicular to each other. In Compact heat exchangers, the heat transfer rate is directly related to pressure loss D. Study Data: This project work has been focused on the improvement in performance of Air Preheater resulting from by modified the existing design and reduction in various heat losses by changing air preheater parameters. By considering data referred by Das et al. [40], was used indirect method for calculation. So, by taking a reference of this indirect method and analysis of various losses this research has been calculated. [4] 1) Water /Steam Parameters: Temperature & pressure measurement of water at economizer inlet and that of steam at boiler outlet. Steam flow rate(steam pressure, steam generation per hour) DM water quality. Feed water analysis. Fuel consumption rate per hour, humidity factor etc. ) Fuel: Collection of fuel samples Ultimate analysis of the fuel(h,o,s,c, Moisture content, ash content) ) Flue Gas/Ash Analysis: Collection of ash samples, for unburnt analysis. Online readings for flue gas analysis. Percentage of oxygen or CO in flue gas. Flue gas in (FGT) 4) Surface Condition: Measurement of surface. Other Data G.C.V of fuel in kcal/kg. Percentage combustible in ash (in case of solid fuel) G.C.V of ash in kcal/kg(in case of solid fuel) Ambient in (Ta) and humidity of air in kg/kg of dry air. Data from heat recover device(if attach) ) Experiment Data [40]: Daily shift wise boiler log sheet format. No. Parameters Unit Quantity 1. Fuel - Indonesian coal. Steam generation rate. Kg/hr. 0,000 Operating hour hr/day Steam pressure Kg/cm Steam. 46. Coal firing rate Kg/hr. 14. G.C.V of coal Kcal/kg. 00. Surface Ambient 10. Humidity factor Table 1: Data for Find out Boiler Efficiency. No. Parameters Value 1. Feed water 160. TDS 00PPM PH.1 Table : Feed water analysis from laboratory All rights reserved by

4 (IJSRD/Vol. 4/Issue 0/016/009) No. Parameters Quantity C 4% H.9% N 1.1% O 4.% A 6% M 1% S 1.% Table : Ultimate analysis of coal from laboratory: No. Parameters Quantity 1. Flue gas 600. % o in flue gas.1% % co in flue gas 11.6% 4. % co in flue gas 0.4% Table 4: Flue gas analysis with flue gas analyzer: No Parameters Quantity 1. G.C.V of bottom Ash 00 kcal/kg. G.C.V of fly Ash 10 kcal/kg Bottom Ash to fly Ash ratio 4. Table : Ash Analysis E. Modeling And Meshing Of Air Preheater: Air preheater is modeled by using Creo Parametric.0. The Creo Parametric is the one of the most efficient modeling software which can use easily modeling and design the objects. After modeling the design of air preheater which can export this file into Finite volume method software because the modal is done for discretizing or meshing process. Fig. 1: Meshing view of Air Preheater (Isometric & Front View) No. Parameters Symbol Unit Quantity 1. Gas quantity W g Kg/hr Air quantity W a Kg/hr 4,000 Air inlet t 1 4. Air outlet t 10.. Flue gas inlet T 1.0 Heat transfer Q KW 14.. Flue gas outlet T 16. Density of flue gas ρ g Kg/m Width of air preheater W m. 10. Depth of air preheater D m Specific heat of air C pa Kcal/kg Specific heat of gas C pg Kcal/kg Thermal conductivity k a Kcal/mh 0.0 of air 14. Thermal conductivity K g Kcal/mh 0.00 of flue gas 1. Viscosity of air µ a Kg/mh Density of air ρ a Kg/m Viscosity of flue gas µ g Kg/mh 0.04 Table 6: Parameters for Air Preheater [40] No. Parameters Unit Value 1. Tube side diameter mm 6. Tube thickness mm.4 Tube inside diameter mm Tube material Carbon steel. Length of tube mm 600 Perpendicular pitch (perpendicular to direction of mm air flow). No. of tube wide Nos 1. No. of tube deep Nos 0 9. Parallel pitch (along the direction of air flow) mm Table : Air Preheater Geometry [] [40] No. Parameters Unit Value 1. Pressure at outlet Gauge 0. Velocity at inlet m/s 1 Wall No slip & escape 4. Default interior Fluid (flue gas) Table : Boundary condition for flue gas [] [40] No. Parameters Unit Value 1. Pressure at outlet Gauge 0. Velocity at inlet m/s 6 Wall No slip & escape 4. Default interior Fluid (air) Table 9: Boundary condition for air [] [40] IV. RESULTS AND DISCUSSIONS A. Simulation Results: The governing equations of the problem were solved, numerically, using a control volume method, and finite element volume (FEV) used in order to calculate the thermo physical properties. As a result of a grid independence study, a various grid size founded for different geometry to model accurately the flow fields described in the corresponding results. The accuracy of the computer model was verified by experimental result and improve the performance of air preheater. In present investigation various results, which are shown in table 4.1, 4. and 4. All rights reserved by

5 (IJSRD/Vol. 4/Issue 0/016/009) N o. 1 4 N o. Tu be Dia met er mm Flue Gas Flow kg/hr Flue gas Temp In O ut Air Temp In O ut Press ure Drop Δp Table 4.1: CFD results for different tube geometry Flu Tub e Flue Gas Air Air e Ga Gas side side Inlet Dia s Inlet pres pres tempe mete flo tempe sure sure rature r w, rature drop drop C mm kg/ C p p hr Hea t Tra nsfe r coef ficie nt w /m C Heat Trans fer Coeff icient w /m C Table 4.: CFD results for different tube diameter parameter Heat Tube Flue Air Gas Air Transf Wor Diam gas gas side side er k eter outlet outlet pres pres Coeffi (mm) temper temper sure sure cient Das et al. [40] Pres ent AN SYS Flue nt 1 Res ult ature C ature C drop p drop p 0. w /m C Table 4.: Validation of results from Das et al. [40] and Present ANSYS Fluent result B. Validation: In this step all results are validated from Das et al. [40] and Present investigation results and concluded the results. Fig. 4.1: Contour plot of Static Pressure in Air Preheater (Tube diameter 4) Figure 4.1 shows the static pressure contour plotting of the air preheater. The pressure at the air inlet is more than at the air outlet. Fig. 4.: Contour plot of static Pressure in Air Preheater (cross section) (Tube diameter 4) All rights reserved by 4

6 (IJSRD/Vol. 4/Issue 0/016/009) Figure 4. shows the static pressure contour plotting of cross section of the air preheater. Figure 4. shows that the radial velocity contour plotting of the air preheater. The contour shows that the flow of air in duct and tube in radial direction. Fig. 4.: Contour plot of Velocity magnitude in Air Preheater (cross section) (Tube diameter 4) Figure 4. shows that the velocity contour plotting of the air preheater. The contour is shows that the flow of air in duct. Fig. 4.6: Contour plot of wall in Air Preheater (Tube diameter 4) Figure 4.6 shows that the contour plotting of wall on the duct and tube walls. Fig. 4.4: Contour plot of Axial Velocity in Air Preheater (Tube diameter 4) Figure 4.4 shows the axial velocity contours which is calculated by ANSYS Fluent software. Fig. 4.: Contour plot Skin Friction Coefficient in Air Preheater (Tube diameter 4) Figure 4. shows that the skin friction coefficient contour plotting of air preheater. The figure indicates that the skin friction coefficient is very low, hence the generation of wall shear stress is also low for increasing heat transfer rate. Fig. 4.: Contour plot of Radial Velocity in Air Preheater (Tube diameter 4) Fig. 4.: Graph plotted between Flue gas outlet and different tube diameter in Das et al. [40] and Present ANSYS Fluent 1 result The figure 4. shows the graph between flue gas outlet and different tube diameters. It indicates that when the diameter of tube decreases flue gas also reduces. All rights reserved by

7 (IJSRD/Vol. 4/Issue 0/016/009) The figure 4.11 shows the graph between air side pressure drop and different tube diameters. It indicates that when the diameter of tube decreases air side pressure drop is increased. Due to increase in air side pressure drop the performance of air preheater is improved. In present investigation the air side pressure drop is 40% more as compare to Das et al. [40]. Fig. 4.9: Graph plotted between air outlet and different tube diameter in Das et al. [40] and Present ANSYS Fluent 1 result The figure 4.9 shows the graph between air outlet and different tube diameters. It indicates that when the diameter of tube decreases air outlet increases. Fig. \4.10: Graph plotted between Flue gas side pressure drop and different tube diameter in Das et al. [40] and Present ANSYS Fluent 1 result The figure 4.10 shows the graph between flue gas side pressure drop and different tube diameters. It indicates that when the diameter of tube decreases flue pressure drop also reduces. In present investigation the flue gas side pressure drop is 1% less as compare to Das et al. [40]. Fig. 4.11: Graph plotted between air side pressure drop and different tube diameter in Das et al. [40] and Present ANSYS Fluent 1 result Fig. 4.1: Graph plotted between heat transfer coefficient and different tube diameter in Das et al. [40] and Present ANSYS Fluent 1 result The figure 4.1 shows the graph between heat transfer coefficient and different tube diameters. It indicates that when the diameter of tube decreases heat transfer coefficient is increased. The present investigation shows that the heat transfer coefficient has increased by 9% as compare to Das et al. [40]. Overall conclusion of the present investigation is that diameter of 4mm is more efficient for air preheater design than 6mm diameter as mentioned in Das et al. [40]. V. CONCLUSION In this thesis mainly focused on the of heat transfer coefficient and heat losses, and increase performance of the air preheater. Also in this thesis, an alternate design of Air preheater has been proposed by using change of air preheater tube parameter. Tube geometry is important design parameters of air preheater modules, since proper selection of tube diameter, thickness, number of tubes in parallel & perpendicular direction etc. results in optimum design of air preheater module. It concluded that when the diameter of tube decreases flue pressure drop also reduces. In present investigation the flue gas side pressure drop is 1% less as compare to Das et al. [40]. It also concluded that when the diameter of tube decreases air side pressure drop is increased. Due to increase in air side pressure drop the performance of air preheater is improved. In present investigation the air side pressure drop is 40% more as compare to Das et al. [40]. Screen covered many results has been founded to be best option in terms of overall size of the air preheater. It can be clearly seen from result tables that as change tube outside diameter from 6 mm to 4 mm, there is All rights reserved by 6

8 (IJSRD/Vol. 4/Issue 0/016/009) saving of 6 to % of tube material. Overall size of air preheater is reduced & results in compact design. When the diameter of tube decreases heat transfer coefficient is increased. The present investigation shows that the heat transfer coefficient has increased by 9% as compare to Das et al. [40]. Overall conclusion of the present investigation is that diameter of 4mm is more efficient for air preheater design than 6mm diameter as mentioned in Das et al. [40]. REFERENCES [1] Science application International Corporation, January 009. Development of issue for GHG Reduction project types: boiler efficiency projects. [] Hjalti Kristinsson,Sofie Long, Dec 010.Boiler Control, Improving Efficiency of Boiler System. [] A.R Malllick Edition Aug.010, Practical Operation Engineering and Power Plants. [4] Brian Elmegaad, Simulation of Boiler Dynamics development, Evaluation & Application of a General Energy System Simulation Tool. [] Er. R. K Rajput, Edition , an Integrated Course In Mechanical Engineering. [6] Boilers & Thermic Fluid Heaters. [] Cleaver Brooks. Facts You Should Know About Fire Tube Boiler & Boiler Efficiency-Boiler Efficiency Guide. [] Energy Performance Assesment of Boiler. [9] Boiler Efficiency Measurement Department of Energy Engineering. [10] A Wienese, 001Boilers, Boiler Fuel and Boiler Efficiency. [11] Chetan T. Patel,Dr. Bhavesh K. Patel,Vijay K. Patel,May 01Efficiency With Different G.C.V Of Coal And Efficiency Improvement Opportunity In Boiler. [1] Bhatia, 01. Improving Efficiency of Boiler System. [1] Boiler Sectional Committee, Hmd 1, Oct 1994 Method of Calculation of Efficiency of Packaged Boilers. [14] Mr. Pawan Kumar, 010.Training Manual on Energy Efficiency for Small & Medium Enterprises. [1] Council of Industrial Boiler Owners, March 00Energy Efficiency & Industrial Boiler Efficiency an Industry Prospective. [16] John Hayton & Alan Shiret,March 009. Boiler Efficiency for Community Heating In Sap. [1] Thomas H. Durkin P. E Member ASHRAE, JULY 00Boiler System Efficiency. [1] Joltan Fabulya, 014.Analysis of the Load- Efficiency Graph Of The Boiler. [19] Method for Determining Boiler Efficiency. [0] Boiler Efficiency Test Protocol. [1] Rahul Patel,May 014Performance Analysis From The Efficiency Estimation Of Coal Fired Boiler. [] Marle R. Likins, 194. Performance Assessment of Fluidized Bed Combustion Boiler. [] Multi Fuel Boiler Efficiency Calculation, Proceeding From the Sixth Annual Industrial Energy Technology Conference Vol.1, Houston. [4] Sachin M. Raut, Sanjay, B. Kumbhe, Krishna C. Thakur,014.Energy Performance Assessment Of Boiler At P.K Ltd. Bashmathnagar, Maharashtra State [] Venkata Seshendra Kumar Karri, 01.Theoritical Investigation of Efficiency Enhancement In Thermal Power Plants. [6] Anjum Munir A.R Tahir,M. Safi Sabir,Khuram Ejaz,004.Efficiency Calculation of Baggasse Fired Boiler On The Basis of Flue Gases Temperature And Total Heat Values Of Steam [] R. Pachaiyappan, J. Dasa Prakash, Improving the Boiler Efficiency By Optimization The Combustion Air. [] P.N Sapkal,P.R Baviskar, Optimization Of Air Preheater Design For The Enhancement of Heat Transfer Coefficient. [9] [0] P.N Sapkal & P.R Baviskar,To Minimize The Air Preheater Design For Better Performance. [1] [] P.M.V Subbarao, Air Preheater For Conservation Of Flue Gas Energy. [] Sreedher Vulloju,Feb 014analysis Of Performance Of Ljungstrom Air Preheater [4] G.Shruti, Vol, Sep.014 performance Evaluation & Optimization of Air Preheater in Thermal Power Plant. [] Mr. Vishwanath, Vol., Sep 014, Heat Transfer Analysis of Recuperative Air Preheater. [6] En.Win-Tech.Cc>Item. [] Exchanger.Com>Plate-Gas [] [9] Kamalengg.Com>Glass-Tube. [40] Ashutosh Kumar Das, THERMODYNAMIC ANALYSIS OF RECUPERATIVE AIR PREHEATER, International Journal of Engineering Sciences & Research Technology, ISSN: -96, 016, pp 6-6 All rights reserved by